WO2013187081A1 - 自動車用防音カバーおよび自動車用防音カバーの製造方法 - Google Patents

自動車用防音カバーおよび自動車用防音カバーの製造方法 Download PDF

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Publication number
WO2013187081A1
WO2013187081A1 PCT/JP2013/050945 JP2013050945W WO2013187081A1 WO 2013187081 A1 WO2013187081 A1 WO 2013187081A1 JP 2013050945 W JP2013050945 W JP 2013050945W WO 2013187081 A1 WO2013187081 A1 WO 2013187081A1
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WO
WIPO (PCT)
Prior art keywords
fiber
flame retardant
mass
soundproof cover
molded body
Prior art date
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PCT/JP2013/050945
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English (en)
French (fr)
Japanese (ja)
Inventor
森　正
要 有水
Original Assignee
ニチアス株式会社
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Filing date
Publication date
Application filed by ニチアス株式会社 filed Critical ニチアス株式会社
Priority to CN201380031063.7A priority Critical patent/CN104379826B/zh
Priority to US14/403,091 priority patent/US20150133019A1/en
Priority to EP13804765.9A priority patent/EP2860294B1/en
Priority to KR1020147032560A priority patent/KR101907244B1/ko
Publication of WO2013187081A1 publication Critical patent/WO2013187081A1/ja

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    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/58—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by applying, incorporating or activating chemical or thermoplastic bonding agents, e.g. adhesives
    • D04H1/587—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by applying, incorporating or activating chemical or thermoplastic bonding agents, e.g. adhesives characterised by the bonding agents used
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60R—VEHICLES, VEHICLE FITTINGS, OR VEHICLE PARTS, NOT OTHERWISE PROVIDED FOR
    • B60R13/00—Elements for body-finishing, identifying, or decorating; Arrangements or adaptations for advertising purposes
    • B60R13/08—Insulating elements, e.g. for sound insulation
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60R—VEHICLES, VEHICLE FITTINGS, OR VEHICLE PARTS, NOT OTHERWISE PROVIDED FOR
    • B60R13/00—Elements for body-finishing, identifying, or decorating; Arrangements or adaptations for advertising purposes
    • B60R13/08—Insulating elements, e.g. for sound insulation
    • B60R13/0838—Insulating elements, e.g. for sound insulation for engine compartments
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60R—VEHICLES, VEHICLE FITTINGS, OR VEHICLE PARTS, NOT OTHERWISE PROVIDED FOR
    • B60R13/00—Elements for body-finishing, identifying, or decorating; Arrangements or adaptations for advertising purposes
    • B60R13/08—Insulating elements, e.g. for sound insulation
    • B60R13/0884—Insulating elements, e.g. for sound insulation for mounting around noise sources, e.g. air blowers
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/42—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/54—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by welding together the fibres, e.g. by partially melting or dissolving
    • D04H1/541—Composite fibres, e.g. sheath-core, sea-island or side-by-side; Mixed fibres
    • D04H1/5412—Composite fibres, e.g. sheath-core, sea-island or side-by-side; Mixed fibres sheath-core
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/54—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by welding together the fibres, e.g. by partially melting or dissolving
    • D04H1/541—Composite fibres, e.g. sheath-core, sea-island or side-by-side; Mixed fibres
    • D04H1/5418—Mixed fibres, e.g. at least two chemically different fibres or fibre blends
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06M—TREATMENT, NOT PROVIDED FOR ELSEWHERE IN CLASS D06, OF FIBRES, THREADS, YARNS, FABRICS, FEATHERS OR FIBROUS GOODS MADE FROM SUCH MATERIALS
    • D06M13/00—Treating fibres, threads, yarns, fabrics or fibrous goods made from such materials, with non-macromolecular organic compounds; Such treatment combined with mechanical treatment
    • D06M13/244—Treating fibres, threads, yarns, fabrics or fibrous goods made from such materials, with non-macromolecular organic compounds; Such treatment combined with mechanical treatment with compounds containing sulfur or phosphorus
    • D06M13/282—Treating fibres, threads, yarns, fabrics or fibrous goods made from such materials, with non-macromolecular organic compounds; Such treatment combined with mechanical treatment with compounds containing sulfur or phosphorus with compounds containing phosphorus
    • D06M13/292—Mono-, di- or triesters of phosphoric or phosphorous acids; Salts thereof
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
    • Y10T442/60—Nonwoven fabric [i.e., nonwoven strand or fiber material]
    • Y10T442/69—Autogenously bonded nonwoven fabric
    • Y10T442/692—Containing at least two chemically different strand or fiber materials

Definitions

  • the present invention relates to a soundproof cover for automobiles and a method for producing a soundproof cover for automobiles.
  • Conventional soundproof covers use a highly rigid cover (rigid cover) molded from metal, polyamide, polypropylene, etc. as a sound insulation material, and the sound emitted from sound sources such as engines according to the law of mass by this rigid cover. Reduced.
  • a sound absorbing material is post-applied to a part or the whole of the inner surface of the rigid cover that faces the sound source, so that the internal reverberation sound (standing wave) is reflected between the sound source and the rigid cover.
  • the rigid body cover and the sound source are separated by suppressing the increase or by providing a rigid body cover for the sound source via a vibration insulator such as a rubber bush (a gap is provided between the rigid body cover and the sound source). It has been studied to suppress the rigid body cover itself from becoming a new sound source due to the solid propagation sound (vibration).
  • the soundproof cover can also be used by directly contacting without providing a sound absorbing material or a gap between the sound source.
  • a soundproof cover that can exhibit high flame resistance for a sound source that is operated at a high temperature, such as an engine, while exhibiting desired soundproofing properties.
  • the present invention provides a soundproof cover for automobiles that can exhibit high flame retardancy while exhibiting desired soundproofness, and also provides a method for easily manufacturing the soundproof cover for automobiles. It is for the purpose.
  • a soundproof cover for automobiles comprising a fibrous molded body containing two or more kinds of fibers, wherein the fibrous molded body is an organic fiber
  • a flame retardant comprising 50 to 80% by mass, 10 to 40% by mass of a flame retardant-containing fiber, and 5 to 20% by mass of an organic binder, and constituting the flame retardant-added fiber with respect to the total mass of the fibrous molded body
  • the present invention (1) A soundproof cover for automobiles comprising a fibrous molded body containing two or more kinds of fibers,
  • the fibrous molded body contains 50 to 80% by mass of organic fibers, 10 to 40% by mass of a flame retardant-containing fiber, and 5 to 20% by mass of an organic binder.
  • the ratio of the total mass of the flame retardant constituting the flame retardant-added fiber to the total mass of the fibrous molded body is 0.01 to 1.8% by mass
  • the automotive soundproof cover, wherein the flame retardant is a melt dripping adjusting agent (2)
  • a mixing step to obtain A method for producing a soundproof cover for automobiles according to (1) or (2), further comprising a fusing step of exposing the fiber assembly to a temperature equal to or higher than the melting point of the low melting point fiber, Is to provide.
  • the automobile soundproof cover of the present invention comprises a fibrous molded body containing two or more kinds of fibers, and the fibrous molded body comprises 50 to 80% by mass of organic fibers and 10 to 10 flame retardant-added fibers. 40% by mass and 5-20% by mass of an organic binder, and the ratio of the total mass of the flame retardant constituting the flame retardant-added fiber to the total mass of the fibrous molded body is 0.01-1.8.
  • the flame retardant is a melt dripping adjusting agent.
  • the flame retardant-containing fiber means a fiber containing a flame retardant inside the fiber
  • the flame retardant-containing fiber includes a fiber containing a flame retardant only inside the fiber, Those containing a flame retardant on the inner and outer surfaces are included, but those containing a flame retardant only on the outer surface of the fiber are excluded.
  • the flame retardant-added fiber those containing 50 to 100% by mass of the flame retardant contained in the flame retardant-added fiber are preferable, and those containing the flame retardant only in the fiber are more preferable.
  • the flame retardant constituting the flame retardant-added fiber is a melt drip regulator, and specifically, as the melt drip regulator, organic phosphoric acid, organic phosphate ester, halogenated One or more selected from organic phosphates can be mentioned.
  • a melt dripping adjusting agent shall mean what can be extinguished by melt dripping even if the automotive soundproof cover ignites in a high temperature environment of 250 ° C. or higher.
  • the melt dripping regulator which is a flame retardant, melts and drops at the time of ignition and extinguishes flame, and is different from general flame retardants. It can also be called.
  • organophosphates or halogenated organophosphates include triphenyl phosphate, tricresyl phosphate, trixylenyl phosphate, cresyl diphenyl phosphate, 2-ethylhexyl diphenyl phosphate, isopropylphenyl diphenyl phosphate, bis- (isopropylphenyl) Diphenyl phosphate, tris- (isopropylphenyl) phosphate, di-2-ethylhexyl hydrogen phosphite, dilauryl hydrogen phosphite, dialkyl hydrogen phosphite, dioleyl hydrogen phosphite, triisooctyl phosphite, diphenyl isodecyl Phosphite, phenyl diisodecyl phosphite, triisodecyl phosphite, trialkyl phosphit
  • a flame retardant such as polyphosphate carbamate, which suppresses the spread of fire to the inside by covering the surface of the combustion source with char (carbonized heat insulating layer) at the time of combustion is not included in the melt dripping adjusting agent.
  • the mass ratio of the flame retardant contained in the flame retardant-added fiber ((mass of flame retardant in the flame retardant-added fiber (g) / mass of flame retardant-added fiber (g)) ⁇ 100)
  • it is usually 1 to 10% by mass, suitably 2 to 8% by mass, and more suitably 3 to 6% by mass.
  • the internally added fiber for the flame retardant constituting the fiber molded body corresponds to (1) a flame retardant polyester in which a flame retardant is dispersed in polyester or a flame retardant in polyester.
  • a flame retardant polyester fibrous material hereinafter referred to as a flame retardant polyester fiber
  • a structural unit or a substituent a structural unit or substituent derived from a flame retardant
  • the above flame retardant Mention may be made of a flame retardant composite fiber in which a polyester and a polyester having a melting point lower than the melting point of the flame retardant polyester fiber (hereinafter referred to as thermal adhesive polyester) are combined.
  • the flame retardant polyester fiber (1) examples include polyethylene terephthalate (PET), polybutylene terephthalate (PBT), polyethylene isophthalate (PEI), polycyclohexylenedimethylene terephthalate (PCHDT), polyethylene naphthalate (PEN), and the like.
  • the polyester include a fiber in which a flame retardant is dispersed and a polyester in which a structural unit or a substituent corresponding to the flame retardant is introduced.
  • the phosphorus content in the flame retardant polyester is preferably about 500 to 10,000 ppm, and preferably 1000 to 5000 ppm. More preferably, it is about.
  • the flame retardant polyester fiber is a product in which a flame retardant is dispersed in polyester, a desired amount of polyester and the flame retardant are mixed and melted, extruded from a die, molded into a fiber shape, and then cooled. It can be suitably produced by a solidifying method (melt spinning method) or the like.
  • Examples of the flame retardant polyester fiber include known ones, such as those described in JP-A-51-82392, JP-A-55-7888, JP-B-55-41610, and the like. Things can be mentioned.
  • a polyester fibrous material obtained by dispersing an organic phosphoric acid compound represented by the following general formula as a flame retardant, or an organic phosphoric acid compound represented by the following general formula is copolymerized.
  • a polyester fibrous material that is chemically bonded by substitution or the like is preferable.
  • R 1 and R 2 are the same or different groups, and each represents a hydrogen atom, a halogen atom or a hydrocarbon group having 6 or less carbon atoms, and R 3 and R 4 are the same. Alternatively, they are different groups and represent a hydrogen atom, a hydrocarbon group having 7 or less carbon atoms, or a group represented by — (R 5 O) r H.
  • R 5 represents an ethylene group, a propylene group or a butylene group
  • r represents an integer of 1 to 10
  • l represents 0 or an integer of 1 to 4
  • n represents 0, 1 or 2.
  • examples of the flame retardant polyester include the same ones as those constituting the flame retardant polyester fiber described above. be able to.
  • the heat-adhesive polyester functions as a binder for the flame retardant polyester, and has a melting point lower than the melting point of the flame retardant polyester. Those having a melting point that is at least 20 ° C. lower than the melting point of the polyester are preferred.
  • the difference between the melting points is less than 20 ° C.
  • high-temperature treatment is required during the production of the flame-retardant composite fiber, so the orientation of the flame-retardant polyester is likely to be reduced, and the reinforcing effect of the heat-adhesive polyester is reduced.
  • the durability of the flame-retardant-added fiber is likely to be lowered, and the physical properties of the flame-retardant polyester as a base material are likely to be lowered.
  • the thermal adhesive polyester preferably has a melting point of 110 ° C. to 220 ° C., more preferably 130 ° C. to 200 ° C.
  • the melting point of the heat-adhesive polyester is within the above range, the reinforcing effect can be easily exerted, and a flame retardant-added fiber excellent in flame retardancy can be easily provided.
  • the melting point of the flame-retardant polyester and the melting point of the heat-adhesive polyester are the orientation when the fiberized product is arranged in a cross shape on the hot plate and heated from room temperature at 5 ° C./min. It means the temperature at which the striped pattern generated by
  • the thermal adhesive polyester is not particularly limited.
  • terephthalic acid isophthalic acid, phthalic acid, p-hydroxybenzoic acid, 5-sodium sulfoisophthalic acid, naphthalenedicarboxylic acid, oxalic acid, adipic acid, sebacic acid,
  • acid components selected from cyclohexylene dicarboxylic acid and the like, and one or more glycols selected from ethylene glycol, diethylene glycol, triethylene glycol, propanediol, butanediol, pentanediol, hexanediol, neopentyl glycol, polyethylene glycol, and the like
  • ester-bonding a component is mentioned.
  • the flame retardant-added fiber is a flame retardant composite fiber in which the flame retardant polyester and the heat adhesive polyester are combined
  • the flame retardant polyester and the heat adhesive polyester are used.
  • the composite ratio is not particularly limited, but the flame retardant polyester content is preferably 20 to 80% by mass, more preferably 30 to 70% by mass, and even more preferably 40 to 60% by mass. .
  • the content ratio of the flame-retardant polyester constituting the flame-retardant composite fiber is within the above range, desired flame retardancy can be easily imparted to the flame-retardant composite fiber.
  • a seascore type in which the flame-retardant polyester is a core component and the heat-adhesive polyester is a sheath component, the flame-retardant polyester and the heat-adhesive polyester are arranged adjacent to each other.
  • a layered multilayer structure type or a side-by-side type can be used.
  • the flame retardant is not exposed on the outer surface.
  • the flame retardant composite fiber is also exposed on the outer surface of the fiber. It is preferable that it is not. Therefore, it is preferable that the flame-retardant composite fiber has a structure in which 50% or more of the outer surface area is occupied by the heat-adhesive polyester. Examples of such a structure include an eccentric sea core type and a multilayer layered structure type. And side-by-side type.
  • the flame retardant composite fiber preferably has a structure in which 100% of the outer surface area is occupied by the heat-adhesive polyester. Examples of such a structure include a seascore type.
  • a hollow sea core type is preferable as the structure of the flame retardant composite fiber, and a deformed hollow sea core type is more preferable.
  • the fibrous molded body constituting the automobile soundproof cover of the present invention is composed of two or more kinds of fibers including a flame retardant-containing fiber, and includes organic fibers described later in addition to the flame retardant-added fiber.
  • the two or more types of fibers constituting the fibrous molded body are short fibers (staples).
  • examples of the organic fiber constituting the fibrous molded body include polyester fiber, polyamide fiber, polyethylene fiber, and polypropylene fiber.
  • the polyester fiber when the organic fiber constituting the fibrous molded body is a polyester fiber, the polyester fiber may be polyethylene terephthalate (PET) fiber, polybutylene terephthalate (PBT) fiber, polyethylene isophthalate (PEI). ) Fiber, polycyclohexylenedimethylene terephthalate (PCHDT) fiber, polyethylene naphthalate (PEN) fiber, and the like.
  • PET polyethylene terephthalate
  • PBT polybutylene terephthalate
  • PEI polyethylene isophthalate
  • PCHDT polycyclohexylenedimethylene terephthalate
  • PEN polyethylene naphthalate
  • the organic fiber constituting the fibrous molded body when the organic fiber constituting the fibrous molded body is a polyamide fiber, the polyamide fiber may be 6-nylon fiber, 6,6-nylon fiber, 11-nylon fiber, 12-nylon. A fiber etc. can be mentioned.
  • the organic fiber constituting the fibrous molded body when the organic fiber constituting the fibrous molded body is a polyethylene fiber, examples of the polyethylene fiber include a low density polyethylene fiber and a high density polyethylene fiber.
  • the organic fiber constituting the fibrous molded body is a polypropylene fiber
  • the polypropylene fiber is a two-layered polypropylene fiber or a two-layered polypropylene resin surface coated with a polyethylene resin to improve adhesion.
  • Examples include structural fibers.
  • the organic binder constituting the fibrous molded body has a melting point lower than the melting point of the organic fiber, or the melting point of the organic fiber or the flame retardant-added fiber. Mention may be made of low-melting fibers having a melting point lower than the melting point.
  • the low-melting fiber is a fiber having a melting point that is at least 20 ° C. lower than the melting point of the organic fiber or a melting point that is at least 20 ° C. lower than the melting point of the organic fiber or the flame retardant-added fiber.
  • the fibrous material has a melting point that is at least 50 ° C. lower than the melting point of the organic fiber, or a melting point that is at least 50 ° C. lower than the melting point of the organic fiber or the flame retardant-added fiber. Is more preferable.
  • the organic binder and the flame retardant-added fiber are easily melted. Can be suitably fused.
  • the organic binder can be appropriately selected and used from those having a melting point of about 80 to 200 ° C.
  • the melting point of the organic fiber, the melting point of the flame retardant-added fiber, and the melting point of the organic binder were determined by placing the fiberized product in a cross shape on a hot plate and raising the temperature from room temperature to 5 ° C./min. Sometimes, it means the temperature at which the striped pattern caused by orientation burns away.
  • examples of the organic binder constituting the fibrous molded body include polyester fibers, thermosetting resins, thermoplastic resin fibers, and the like.
  • the polyester fiber includes polyethylene terephthalate (PET) fiber, polybutylene terephthalate (PBT) fiber, polyethylene isophthalate (PEI). ) Fiber, polycyclohexylenedimethylene terephthalate (PCHDT) fiber, polyethylene naphthalate (PEN) fiber and the like.
  • PET polyethylene terephthalate
  • PBT polybutylene terephthalate
  • PEI polyethylene isophthalate
  • PCHDT polycyclohexylenedimethylene terephthalate
  • PEN polyethylene naphthalate
  • the thermosetting resin when the organic binder constituting the fibrous molded body is a thermosetting resin, the thermosetting resin may be a thermosetting phenol resin, an epoxy resin, a melamine resin, a urea resin, One or more selected from saturated polyester resins, alkyd resins, polyurethane resins, thermosetting polyimide resins and the like can be mentioned.
  • the thermoplastic resin when the organic binder constituting the fibrous molded body is a thermoplastic resin, the thermoplastic resin may be polyethylene resin, polypropylene resin, polystyrene resin, polyvinyl acetate resin, polyvinyl acetate- Examples thereof include one or more selected from ethylene copolymer resins, acrylonitrile-butadiene-styrene (ABS) resins, acrylonitrile-styrene (AS) resins, acrylic resins, methacrylic resins, and the like.
  • ABS acrylonitrile-butadiene-styrene
  • AS acrylonitrile-styrene
  • the fibrous molded body contains 50 to 80% by mass of organic fibers, 10 to 40% by mass of flame retardant-added fibers, and 5 to 20% by mass of organic binder.
  • the content of the organic fibers constituting the fibrous molded body is 50 to 80% by mass, preferably 55 to 75% by mass, and preferably 60 to 70% by mass. More preferred.
  • the content ratio of the organic fibers constituting the fibrous molded body is within the above range, desired soundproofing properties and the like can be imparted to the fibrous molded body.
  • the content ratio of the flame retardant-containing fiber constituting the fiber molded body is 10 to 40% by mass, preferably 15 to 35% by mass, and 20 to 30% by mass. More preferably.
  • the content ratio of the flame retardant-containing fiber constituting the fiber molded body is within the above range, desired flame retardancy and the like can be imparted to the fiber molded body. .
  • the content of the organic binder constituting the fibrous molded body is 5 to 20% by mass, preferably 5 to 15% by mass, and preferably 7 to 15% by mass. More preferred.
  • the fiber molding is performed while containing the organic fiber and the flame-retardant internal additive fiber in a desired ratio. Desired flame retardancy and soundproofing can be easily imparted to the body.
  • the ratio of the total mass of the flame retardant constituting the flame retardant-containing fiber to the total mass of the fiber molded body ((total mass of the flame retardant constituting the flame retardant-added fiber (g) / Total mass (g)) of fibrous molded body ⁇ 100) is 0.01 to 1.8% by mass, preferably 0.1 to 1.8% by mass, preferably 0.5 to 1.%. It is more preferable that it is 6 mass%.
  • the ratio of the total mass of the flame retardant constituting the flame retardant-added fiber to the total mass of the fiber molded body is within the above range, so that the desired flame retardancy (flame extinction) is achieved. Can be granted.
  • the soundproof cover for automobiles according to the present invention can exhibit desired flame retardancy (flame extinction) when the fibrous molded body contains a desired amount of flame retardant-containing fibers.
  • flame retardant flame extinction
  • the fiber molded body is not a flame retardant-added fiber but contains a flame retardant itself or a fiber in which the flame retardant is present only on the outer surface, the flame retardant tends to be unevenly distributed on the outer surface of the fiber molded body.
  • UL Underwriters Laboratories
  • V-0 test flammability test
  • the ratio of the total mass of the flame retardant constituting the flame retardant-added fiber to the total mass of the fibrous molded body is too small, the total combustion time in the UL-94 V-0 test becomes long, and the fibrous molded body If the ratio of the total mass of the flame retardant composing the flame retardant-added fiber to the total mass is too large, the fire spread distance in the UL-94 V-0 test becomes long.
  • the fibrous molded body preferably has a total combustion time of 50 seconds or less in the UL-94 V-0 test, more preferably 45 seconds or less, and 40 seconds or less. Some are more preferred.
  • the total burning time is defined as 10 operations in which the upper 10 mm of a strip-shaped test piece (127 mm in length and 12.7 mm in width) is clamped and brought into contact with the bottom of the test piece, and then the flame is removed. It means the total flaming combustion time when repeated.
  • the fibrous molded body preferably has a fire spread distance of 117 mm or less in the UL-94 V-0 test, more preferably 115 mm or less, and 110 mm or less. More preferred.
  • the fire spread distance is the flame extinction when the flame is released after contacting the bottom of the test piece with the upper 10 mm of a strip-shaped test piece (127 mm long, 12.7 mm wide) clamped. It means the length of the test piece that has been fired.
  • the fibrous molded body preferably has a red heat time of 30 seconds or less, more preferably 20 seconds or less in the UL-94 V-0 test, and 10 seconds or less. More preferred.
  • the above-mentioned red hot time is the test when the flame is released after contacting the bottom of the test piece with the upper 10 mm of a strip-shaped test piece (length 127 mm, width 12.7 mm) held between clamps. It means the time when the piece has turned red.
  • the fibrous molded body is such that the molten drop does not have combustibility in the UL-94 V-0 test.
  • the molten drop does not have flammability means that a strip-shaped test piece (length 127 mm, width 12.7 mm) is held in contact with the bottom of the test piece with the upper 10 mm clamped and ignited. Then, after the flame is removed, it means that the molten drop that is dropped when the flame is extinguished does not ignite the absorbent cotton disposed under the drop.
  • the fibrous molded body preferably has a ventilation resistance of 1.4 ⁇ 10 4 to 2.5 ⁇ 10 4 (Pa ⁇ second / m 2 ), and 1.5 ⁇ More preferably, it is 10 4 to 2.4 ⁇ 10 4 (Pa ⁇ second / m 2 ), and further preferably 1.6 ⁇ 10 4 to 2.3 ⁇ 10 4 (Pa ⁇ second / m 2 ). preferable.
  • the performance as a sound absorbing material (sound absorption rate) and the dropping rate at the time of ignition are easily maintained within an appropriate range by the ventilation resistance of the fiber molded body being within the above range. can do.
  • ventilation resistance shall mean the value measured by JISL1096: 2000.
  • the fibrous molded body preferably has a Young's modulus of 1.5 ⁇ 10 4 to 8.0 ⁇ 10 4 (Pa), and 1.6 ⁇ 10 4 to 7. It is more preferably 0 ⁇ 10 4 (Pa), and further preferably 1.6 ⁇ 10 4 to 6.0 ⁇ 10 4 (Pa).
  • the desired strength can be easily exhibited when the Young's modulus of the fibrous molded body is within the above range.
  • Young's modulus shall mean the value measured by the method based on JISK7127.
  • the bulk density of the fibrous molded body is preferably 0.005 to 0.4 g / cm 3 , more preferably 0.01 to 0.2 g / cm 3. 0.025 to 0.1 g / cm 3 is more preferable.
  • the bulk density of the fibrous molded body is within the above range, voids can be formed in the fibrous molded body at a desired ratio, and for this reason, it is based on air viscosity resistance. Sound absorption characteristics can be effectively exhibited.
  • the bulk density of the fibrous molded body (g / cm 3), at room temperature to measure the mass of the fibrous molded body M (g) and volume V (cm 3), the mass M Is calculated by dividing V by volume V (determining M / V).
  • the fibrous molded body preferably has a basis weight of 150 to 2000 g / cm 2 , more preferably 250 to 1500 g / cm 2 , and 500 to 1000 g / cm 2. More preferably, it is 2 .
  • the fabric weight (g / cm ⁇ 2 >) of a fibrous molded object shall mean the value calculated from the mass of a 10-cm square square-shaped fibrous molded object.
  • the thickness of the fibrous molded body is preferably 1 to 100 mm, more preferably 1.5 to 50 mm, and still more preferably 1.5 to 30 mm.
  • the soundproof cover for automobiles of the present invention when the thickness of the fibrous molded body is within the above range, the sound absorption characteristics can be effectively exhibited.
  • the thickness of the fibrous molded body can be measured, for example, with calipers.
  • the soundproof cover for automobiles of the present invention can be used as a soundproof cover for automobile engines, transmissions, drive system devices, etc., and is particularly suitable as a soundproof cover for engines.
  • the automobile soundproof cover of the present invention may be used as it is made of the above-mentioned fibrous molded body, or may be used as a soundproof cover with a skin material provided with a skin material on the outer surface.
  • FIG. 1 is a view showing an example of a soundproof cover for automobiles according to the present invention
  • FIG. 1A shows a perspective view of the soundproof cover 1 for automobiles having a skin material 2.
  • FIG. 2B is a schematic diagram showing a cross section taken along line AA ′ of FIG.
  • the skin material 2 is provided on the outer surface of the automobile soundproof cover 1.
  • synthetic resin fibers such as polyester fibers and polypropylene fibers, natural fibers such as pulp fibers and kenaf fibers, glass fibers, Nonwoven fabrics and woven fabrics made of organic fibers or inorganic fibers such as metal fibers, ceramic fibers, and carbon fibers can be given.
  • the nonwoven fabric or woven fabric preferably has a basis weight of 50 g / cm 2 to 600 g / cm 2 , more preferably 150 g / cm 2 to 400 g / cm 2 .
  • the skin material 2 in order to ensure adhesion to the soundproof cover 1 and vibration damping properties, vinyl acetate resin, vinyl acetate-ethylene copolymer resin, acrylic resin, acrylonitrile-styrene-butadiene copolymer are used as viscoelastic materials. What formed by apply
  • coating resin such as polymer resin, a silicone resin, and a moisture hardening reaction type urethane resin, is preferable.
  • the application amount of the viscoelastic material is preferably 100 g / cm 2 to 600 g / cm 2, and more preferably 200 g / cm 2 to 600 g / cm 2 .
  • the inner surface 3 of the soundproof cover 1 is a surface facing the engine as a sound source, and the inner surface 3 is made of non-woven fabric, woven fabric, foamed vermiculite pieces, mascobite, biotite, etc. to prevent scattering and reinforcement. You may cover with the porous coating film which hardened the scaly clay mineral with the binder.
  • the soundproof cover for automobiles of the present invention can be suitably produced by, for example, a method for producing a soundproof cover for automobiles of the present invention described later.
  • the soundproof cover for example, when a soundproof cover is ignited from a spark plug in an automobile and the soundproof cover ignites, the vicinity of the ignition part is short because the soundproof cover includes a predetermined amount of the melt-dropping regulator. Since it melts and drops (melts down) while extinguishing at the time of melting, not only the subsequent fire spread can be suppressed, but also the molten drop can be dropped on the ignition source to extinguish the ignition location. For this reason, according to this invention, the soundproof cover for motor vehicles which consists of a fiber molded object which can exhibit high flame retardance (flame extinction) can be provided, exhibiting desired soundproofing property.
  • the method for producing a soundproof cover for automobiles according to the present invention comprises 50 to 80% by mass of organic fiber, 10 to 40% by mass of a flame retardant-added fiber, and 5 to 20% of low melting point fiber having a melting point lower than the melting point of the organic fiber. %, And a fusion step of exposing the fiber assembly to a temperature equal to or higher than the melting point of the low-melting fiber.
  • examples of the organic fiber and the flame retardant-containing fiber include the same ones as described above.
  • examples of the low melting point fiber having a melting point lower than the melting point of the organic fiber include the same ones as described above.
  • the melting point of the low-melting fiber is preferably about 80 to 200 ° C.
  • organic fibers, flame retardant-containing fibers, and low-melting fibers having a melting point lower than the melting points of the organic fibers and the flame-retardant-added fibers Mix first, in the mixing step, organic fibers, flame retardant-containing fibers, and low-melting fibers having a melting point lower than the melting points of the organic fibers and the flame-retardant-added fibers Mix.
  • the method for producing a soundproof cover for automobiles according to the present invention includes, in the mixing step, 50 to 80% by mass of organic fibers, 10 to 40% by mass of flame retardant-added fibers, and a melting point of the organic fiber and flame retardant-added fibers. 5 to 20% by mass of a low-melting fiber having a low melting point, 55 to 75% by mass of organic fiber, 15 to 35% by mass of flame retardant-containing fiber, and organic fiber and flame retardant-added fiber.
  • a low-melting fiber having a melting point lower than the melting point 60 to 70% by mass of organic fiber, 20 to 30% by mass of a flame retardant-containing fiber, More preferably, 7 to 15% by mass of a low melting point fiber having a melting point lower than the melting point of the flame retardant-containing fiber is mixed.
  • the mixing of the organic fiber, the flame retardant-added fiber and the organic binder in the mixing step can be performed using various mixing devices, and the mixing device includes various mixers.
  • a three roll mill, a bead mill, an extruder, a kneader, etc. can be mentioned.
  • the mixing conditions by the mixing device can be appropriately set so that the organic fiber, the flame retardant-added fiber and the organic binder can be uniformly dispersed.
  • a fiber assembly can be obtained by forming into a shape approximating the target shape using a mold or the like as desired.
  • the manufacturing method of the soundproof cover for automobiles of the present invention includes a fusing step of exposing the fiber assembly to a temperature higher than the melting point of the low melting point fiber.
  • the fiber assembly is exposed to a temperature equal to or higher than the melting point of the low-melting fiber, which is higher than the melting point of the organic fiber constituting the fiber assembly and the melting point of the flame retardant-containing fiber.
  • a temperature equal to or higher than the melting point of the low-melting fiber which is higher than the melting point of the organic fiber constituting the fiber assembly and the melting point of the flame retardant-containing fiber.
  • the soundproof cover 1 and the skin material 2 are joined, for example, in a state in which both are laminated. It can be performed by hot press molding using a pair of upper and lower molds having a molding surface corresponding to the outer shape of a sound source such as an engine.
  • the hot press molding the soundproof cover 1 and the skin material 2 are bonded by the viscoelastic material applied to the skin material 2 and molded into a desired shape.
  • the molding temperature is preferably equal to or higher than the curing temperature of the viscoelastic material applied to the skin material 2, and the molding pressure is appropriately set according to the target thickness of the soundproof cover 1.
  • the upper mold and the lower mold constituting the mold a soundproof cover with a skin material in which the peripheral end 4 is integrally formed can be obtained by using a flat peripheral end portion.
  • the soundproof cover for cars that can exhibit high flame retardancy while exhibiting desired soundproofing properties can be easily manufactured by having the mixing step and the fusion step. can do.
  • Example 1 to Example 6, Comparative Example 1 to Comparative Example 2 Comparative Example 1 to Comparative Example 2.
  • Polyethylene terephthalate (PET) fiber (melting point 230 ° C.) or 6-nylon fiber (melting point 225 ° C.) is used as the organic fiber, and tris ( ⁇ -chloro, which is a flame retardant, is added to the polyester as a flame retardant-added fiber.
  • PET polyethylene terephthalate
  • ⁇ -chloro which is a flame retardant
  • each fiber was blended under the blending ratio shown in Table 1 so that the ratio of the total mass of the flame retardant constituting the fiber added with the flame retardant to the total mass of the molded product was the ratio shown in Table 1 (dry type) To obtain each fiber assembly.
  • Table 1 the ratio (mass%) of the total mass of the flame retardant composing the flame retardant-added fiber to the total mass of each fiber molded body obtained is simply expressed as “content ratio of flame retardant”. Yes.
  • the non-flammability pass / fail judgment criteria are as follows: the total burning time in the UL-94 V-0 test is 50 seconds or less, the fire spread distance is 117 mm or less, the red hot time is 30 seconds or less, and the molten cotton is combustible and does not ignite absorbent cotton. In the case where it was determined that the above criteria were all satisfied, the overall judgment was “accepted”, and those that did not satisfy any of the above criteria were designated as the overall judgment “failed”. The results are shown in Table 1 (in Table 1, “> 50” means “over 50 seconds” and “> 117” means “over 117 mm”).
  • Example 7 instead of the flame-retardant polyester fiber in which 4% by mass of tris ( ⁇ -chloropropyl) phosphate, which is a flame retardant, is dispersed in polyester as a flame retardant-containing fiber used in the mixing step, polyester A flame retardant polyester fiber in which 2% by mass of tris ( ⁇ -chloropropyl) phosphate as a flame retardant is dispersed is used (Example 7), or tris ( ⁇ -chloropropyl) as a flame retardant in polyester Using a flame-retardant polyester fiber in which 8% by mass of phosphate is dispersed (Example 8), each fiber assembly having the composition shown in Table 2 is obtained in the same manner as in Example 3, and then the fusing step is performed.
  • Example 3 instead of the flame retardant polyester fiber in which 4% by mass of tris ( ⁇ -chloropropyl) phosphate, which is a flame retardant, is dispersed in polyester as the flame retardant internal fiber used in the mixing step, tris Either 4% by mass of ( ⁇ -chloropropyl) phosphate is coated on the outer surface of the polyester fiber (Comparative Example 3) or the flame retardant tris ( ⁇ -chloropropyl) phosphate itself (Comparative Example 4). Each component was mixed in the same manner as in Example 3 to obtain each fiber assembly having the composition shown in Table 3, and then subjected to a fusion process to form a fiber having a felt-like porous shape. Got the body.
  • Example 9 In Example 3, instead of the flame-retardant polyester fiber in which 4% by mass of tris ( ⁇ -chloropropyl) phosphate, which is a flame retardant, is dispersed in polyester as a flame retardant-containing fiber used in the mixing step, polyester Using a flame retardant polyester fiber in which 5% by mass of chloropropyl phosphate as a flame retardant was dispersed, a fiber assembly having the composition shown in Table 4 was obtained in the same manner as in Example 3, and then fused. The process was given and the fibrous molded object which has a felt-like porous shape was obtained. In Table 4, the ratio (mass%) of the total mass of the flame retardant constituting the flame retardant-added fiber with respect to the total mass of each obtained fiber molded body is simply expressed as “content ratio of flame retardant”. Yes.
  • the fibrous molded bodies obtained in Examples 1 to 9 were 50 to 80% by mass of organic fibers, 10 to 40% by mass of flame retardant-containing fibers, and 5 to 20 organic binders.
  • the ratio of the total mass of the flame retardant constituting the flame retardant-containing fiber to the total mass of the fibrous molded body is 0.01 to 1.8 mass%, and the flame retardant is By being a melt dripping adjusting agent, it can exhibit high flame retardancy (flame extinguishing) while exhibiting desired soundproofing properties. For this reason, it can be suitably used as a soundproofing cover for automobiles. I know that there is. Further, in Examples 1 to 9, it can be seen that the above-mentioned fibrous molded body can be easily manufactured, and for this reason, the target automobile soundproof cover can be easily manufactured.

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  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Physics & Mathematics (AREA)
  • Acoustics & Sound (AREA)
  • Mechanical Engineering (AREA)
  • Vehicle Interior And Exterior Ornaments, Soundproofing, And Insulation (AREA)
  • Nonwoven Fabrics (AREA)
  • Soundproofing, Sound Blocking, And Sound Damping (AREA)
  • Compositions Of Macromolecular Compounds (AREA)
PCT/JP2013/050945 2012-06-12 2013-01-18 自動車用防音カバーおよび自動車用防音カバーの製造方法 WO2013187081A1 (ja)

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CN201380031063.7A CN104379826B (zh) 2012-06-12 2013-01-18 汽车用防音罩和汽车用防音罩的制造方法
US14/403,091 US20150133019A1 (en) 2012-06-12 2013-01-18 Soundproof cover for automobile and method for manufacturing soundproof cover for automobile
EP13804765.9A EP2860294B1 (en) 2012-06-12 2013-01-18 Soundproof cover for automobile and method for manufacturing soundproof cover for automobile
KR1020147032560A KR101907244B1 (ko) 2012-06-12 2013-01-18 자동차용 방음 커버 및 자동차용 방음 커버의 제조 방법

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US9533630B2 (en) 2014-10-29 2017-01-03 Nonwoven Network LLC High performance moldable composite
US9938659B2 (en) 2015-06-27 2018-04-10 Nonwoven Network LLC Apparatus and method of making a nonwoven ceiling tile and wall panel
JP6313841B1 (ja) * 2016-12-13 2018-04-18 ユニチカ株式会社 自動車装備材用半製品の製造方法
IT201700019731A1 (it) * 2017-02-22 2018-08-22 Sapa S R L Metodo multifase di produzione di una cover composita insonorizzata per motori a combustione interna e prodotto così ottenuto.
WO2018174070A1 (ja) 2017-03-23 2018-09-27 株式会社イノアックコーポレーション 防音材及びその製造方法
JP7105073B2 (ja) * 2017-03-23 2022-07-22 株式会社イノアックコーポレーション 防音構造
KR102390530B1 (ko) * 2017-04-12 2022-04-25 유니티카 가부시끼가이샤 니들 펀치 부직포의 제조 방법
JP6671690B2 (ja) * 2017-04-19 2020-03-25 ユニチカ株式会社 繊維ボードの製造方法
KR102144516B1 (ko) * 2018-11-12 2020-08-13 플렉스폼코리아 유한회사 엔진커버용 복합보드 및 그 제조방법
WO2020230176A1 (en) * 2019-05-13 2020-11-19 Isp S.R.L. Soundproofing cover for an engine
JP7473315B2 (ja) * 2019-10-03 2024-04-23 ニチアス株式会社 防音部材
CN111892773A (zh) * 2020-07-29 2020-11-06 广西德福特科技有限公司 一种具有阻燃性能的双组份吸音棉及其制备方法和应用
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CN112080856B (zh) * 2020-09-21 2021-11-05 凌扬汽车制造有限公司 一种房车用复合吸音材料的制备方法
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EP2860294A1 (en) 2015-04-15
EP2860294B1 (en) 2017-08-16
CN104379826B (zh) 2016-09-21
KR101907244B1 (ko) 2018-10-11
JP2013256733A (ja) 2013-12-26
CN104379826A (zh) 2015-02-25
EP2860294A4 (en) 2016-03-02
US20150133019A1 (en) 2015-05-14
JP5174980B1 (ja) 2013-04-03

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